Durable glass fiber reinforced panel

Abstract

A durable composite sheet is provided, with a method of manufacturing the composite sheet. The method includes using a crack-resistant reinforcement panel between a gel coat and a reinforcement panel, which may be of lauan or of other materials. At least one outer coat of material is applied onto a mold surface. A barrier layer may be formed on the outer coat, preferably by spraying. At least one coat of a resin material, containing a curable resin and optionally a filler, and a fibrous reinforcement material are applied over the outer coat (over the barrier layer if present) to form a reinforcement layer. The reinforcement panel is applied to the crack-resistant reinforcement layer, and is bonded thereto.

1. A composite sheet, comprising:
 at least one outer coat of material; 
 at least one coat of a resin material and reinforcement material on the outer coat to form a first reinforcement layer, the resin material comprising a curable resin; and 
 a reinforcement panel on and bonded to the first reinforcement layer, 
 wherein the resin material further contains a filler that comprises hollow micro-capsules that contain materials that, upon rupture of a given one of the micro-capsules, mix and react to form a material compatible with the resin of the resin material that bonds with an adjacent portion of the first reinforcement layer. 
 
     
     
       2. The composite sheet according to  claim 1 , wherein the filler material further comprises a material selected from the group consisting of calcium carbonate and mica. 
     
     
       3. The composite sheet according to  claim 1 , wherein the resin is a low-shrinkage resin. 
     
     
       4. The composite sheet according to  claim 1 , wherein the glass-fiber reinforcement material includes fibrous reinforcement material that comprises glass fibers having a nominal length of about 0.5 in. to about 1.0 inch. 
     
     
       5. The composite sheet according to  claim 1 , wherein the glass-fiber reinforcement material includes fibrous reinforcement material that comprises glass fibers which predominantly have a nominal length of about 0.5 inch. 
     
     
       6. The composite sheet according to  claim 1 , further comprising a barrier layer provided between the outer coat and the first reinforcement layer, the barrier layer comprising a curable resin, and optionally either fibers or a filler or both.